HAWKINSON NDT -INSP 2, REBUILD & UPGRADE NDT®-INSP 2, REBUILD & UPGRADE OPERATOR’S MANUAL ® The...

HAWKINSON NDT®-INSP 2,REBUILD & UPGRADEOPERATOR’S MANUAL

®

The safety alert symbol means CAUTION, WARNING or DANGER—personal safety instruc-tion. Failure to comply with the instruction may result in personal injury.

To assure maximum safety and optimum performance, it is essential that you or any otheroperator of the NDT-II® read and understand the contents of this manual before operating themachine. Pay particular attention to the SAFETY INSTRUCTIONS highlighted by this symbol—

12/4/94 UPGRADE—WITH TEI MOTOR CONTROLLER 115/230 VAC

12/7/94

Congratulations.

You have purchased the most cost-effective product on themarket today to detect penetrations, nails, nail holes, cuts,tears, and bad repairs in tires. The Hawkinson NDT®-II is alsodurable and easy to operate. It can be used at any point inthe retread process, including after retreading. Neither infla-tion nor buffing are needed before testing.

We’ve designed this manual to help you get started quickly.We recommend you start at the beginning, and pay carefulattention to the Safety section.

We stand behind our product. We are a family-owned compa-ny that has been in the retreading business since 1931. If youhave questions, need assistance, or wish to suggest improve-ments, please don’t hesitate to call.

HAWKINSON TREADING, INC.1325 Winter Street N.E.

Minneapolis, MN 55413 USAPhone (612) 331-1397 • FAX (612) 331-6569

2

12/7/94

TABLE OF CONTENTS

Safety 4

Introduction 7

Installation 9

Controls 14

Operation 18

Maintenance 24

Wiring Diagrams 28–31

Air System Diagram 32

Parts Lists 33–42

3

The Hawkinson NDT®-INSP 2 is the most effective product available for detectingholes and imbedded nails in tires being prepared for retreading. However, becauseof the high voltages it employs, operators must exercise caution.

Please be sure that all warning labels are always visible on the Control and DisplayCabinet and on the Instpector. These warning labels are in the following areas.

1. On the door of the Electronics Cabinet as shown in Figure 1.

Figure 1

SAFETY

412/7/94

This safety alert symbol means CAUTION, WARNING OR DANGER—“personal safety instruction.” Read and understand the instructionbecause it has to do with safety. Failure to comply with the instruc-tion may result in personal injury.

NDT ElectronicsCabinet®

WARNING• The voltages inside this cabinet are lethal!

• Disconnect power before opening cabinet.

• Never operate this machine with the cabinet door open!

• Be sure the electrical connections are properly grounded.

WARNING• The voltages inside this cabinet are lethal!

• Disconnect power before opening cabinet.

• Never operate this machine with the cabinet door open!

• Be sure the electrical connections are properly grounded.

The NDT®-INSP 2 electrical cabinet should only be opened by qualified, trained

electrical personnel. It should not be opened by regular operators!

DANGER!

2. On the 50 kv power supply (Figure 2).

Figure 2

3. On the right-hand side of the control and display cabinet as shown below.

Figure 3

SAFETY

512/7/94

DANGER

• Lethal high voltage! Can cause death.

• Do NOT enter this cabinet with the AC voltage on.

4. On the Inspector probe arm.(Figure 4)

Figure 4

SAFETY

612/7/94

WARNING• High Voltage

• This tire test probe can cause electical shock.

• Keep hands and foreign objects away from probe during testing.

• Do not touch tire while it is being tested.

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All Hawkinson NDTs operate on the principle that small flaws in electrical insulat-ing materials (and rubber) can be found using high-voltage, high-intensity electri-cal fields. For example, consider an ordinary electrical cord: as long as the cord’sinsulation is sound, the electricity is contained and it flows in moderate amounts.However, if the insulation is flawed, an arc can develop between the two conduc-tors. Very high current then flows, and a fuse or circuit breaker detects the highcurrent and shuts down the circuit.

When using an NDT®-INSP 2, the rubber in the tire is the insulator. You insert ahigh-voltage probe into the tire opposite a grounded roller (Figure 4). If the tire issound, minimal current flows. If the tire is flawed, an arc occurs. This arc is brightand easily visible. Also, as the current flows through the penetrations, the NDT®-INSP 2 detects it and warns of the flawed condition.

Figure 5

The type of high-voltage pulse the NDT®-INSP 2 uses is different for fabric and steeltires. (You select the correct voltage at the console with a two-postion switch.)

The NDT®-INSP 2 detects the following flaws for fabric and steel tires (Figures 6 and7 on the next page.)

INTRODUCTION

712/7/94

Grounded Roller

•

•

•AMPS

100

NDTElectronics

®

FLAW

Flawed Tire

•

•

High-voltageprobe

DTectronics

®

•Grounded Roller

AMPS

100Sound Tire

High-voltageprobe

INTRODUCTION

812/7/94

CBA

Grounded Roller

Tread

Inner Liner

Arc

—Open Holes—Inner Liner Penetrations—Nails Still in Tire Tread

Belt

CBA

Grounded Roller

Tread

Arc

A—Open HolesB—Treaded-Over HolesC—Nails Still in Tire

Inner Liner

Cord

Figure 7 Arcing Through Steel Tires

Figure 6Arcing Through Fabric Tires

Your NDT®-INSP 2 will be equipped with an electrical system compatible with theelectrical system in your area. Wiring for three different types of electrical systemsis shown below.

INSTALLATION

912/7/94

CABINET

G12

GROUND (GREEN)HI (BLACK)LO (WHITE)

HI (BLACK)LO (WHITE)

GROUND (GREEN)

1819G

120 VAC

230 VAC

TERMINALBOARD

Type 1. Electrical Installation(North American Version)

120 volt and 230 volt, 60 hzSingle Phase

STEP 1 Unpack the NDT®-INSP 2 and position it where it will be operated.

The two main components of the Hawkinson NDT®-INSP 2 are theInspector and the Control Cabinet. Both are bolted down to wooden pal-lets. Be careful not to damage the machine as you remove the crates.

The head of the Inspector is wrapped in a plastic bag which also containsspare parts. Carefully remove this bag.

Figure 8

INSTALLATION

1012/7/94

ControlCabinet

Branick ModelSFLL/ER/EF

16"22"

74"

26" 6" 40"

12"

= 1/4" air line 150 psi Maximum filtered service

Required Floor Plan For NDT®-INSP 2

STEP 2 Position the NDT®-INSP 2 according to the floor plan shown below.

STEP 3 Make the seven cable connections between the Inspector and the Control Cabinet (see Figure 10, next page) in the following order.

1. Connect the two electrical connection (cables 1 and 2 inFigure 10).

2. Connect the two connections to the air regulators (cables 3

Figure 9

and 4 in Figure 10).

3. Connect the black cable (cable 5 in Figure 10).

4. Connect the ground cable (cable 6 in Figure 10)

The ground cable attaches to the metal panel screw in theInspector that will be closest to the Cabinet (this provides thebest electrical connection and minimuizes the risk of acciden-tally being pulled out during operation). This screw is markedwith a little tag.

5. Connect the high-voltage cable (cable 7 in Figure 10).

Run the yellow high-voltage cable through the control cabinet.

INSTALLATION

1112/7/94

①②

③④

⑥

②①

④③

⑥

⑤

⑤

Inspector Cabinet

(Rear View)

⑦

⑦

Figure 10

The 7 installation connections for the Hawkinson NDT®-INSP 2 Tire Casing Inspector

6. Connect the high-voltage cable to the 150 ohm resistor as shown inFigure 11.

Step 4 After connecting all seven cables, tie cables 1, 2, 3, 4, and 5 together sothat the wires will be less likely to be accidentally disconnected

Step 5 Close and lock the cabinet door. NEVER OPEN THIS DOOR WITHOUTFIRST DISCONNECTING ALL ELECTRICAL POWER.

INSTALLATION

1212/7/94

Figure 11

Yellowhigh-voltage wire

Coil wireCautionMake sure the coil wireis positioned as far as possible fromthis connection pointto prevent shorting.

AWAY

STEEL FABRIC

STEEL FABRIC

FOR REVOFFMANUALSTART

FUSE

OUT INARM SWING

UP DOWNINSIDE

OFF ONHIGH VOLTAGE

TESTOVERFLAW

OFFONPOWER

0 100

50

80

High-voltage wireconnection point

COIL Relay

C A U T I O N• IMPROPER USE COULD CAUSE ELECTRICAL SHOCK

• DISCONNECT POWER BEFORE OPENING BOX

H I G H V O L T A G E

STEP 6 Set the switches on the control cabinet to the following positions.

STEP 7 Plug in the connections to your electrical outlets.

STEP 8 Connect the air supply (Figure 12). The main air pressure regulatorshould be set at 40 psi (2.7 bar), the down pressure of the high-voltageprobe should be 2 psi (0.33 bar), the up pressure on the high-voltageprobe should be just enough to raise it without stressing the tire sidewallshould it make contactwhen rising.

STEP 9 Review the previous installation steps, making sure all cables are correctlyinstalled and secure.

INSTALLATION

1312/7/94

Inspector(Rear)

AirConnection

OUT INARM SWING

UP DOWNINSIDE

Figure 12

Please begin by acquainting yourself with the NDT®-INSP 2control panel. Each of the panel’s components is described inthe following pages.

CONTROLS

1412/7/94

STEEL FABRIC

STEEL FABRIC

TESTOVERFLAW

OUT INARM SWING

UP DOWNINSIDE


OFFONPOWER

OFF ONHIGH VOLTAGE

0 100

50

Figure 13The Hawkinson NDT®-INSP 2 CONTROL PANEL

12/7/94 15

CONTROLS

OFFONPOWER POWER (keyed, two-position switch)

This switch operates with a key that you can remove when the switch is ineither position. After you use the key to turn the power on, remove thekey and use it to turn the HIGH-VOLTAGE switch on or off.

This switches the machine to either the FABRIC or STEELtesting system. The two pilot lights (120 volts) on eitherside show which system you selected.

IMPORTANT: The FABRIC testing system uses highervoltage than the STEEL testing system. If you selectthe FABRIC testing system for a radial tire and apply itto the tire for too long, you may damage the tire.

OFF ONHIGH VOLTAGE HIGH VOLTAGE (keyed, two-position switch)

This switch, which must be in the ON position for the machine to operate,uses a key. The switch must be in the OFF position before you can put thekey in or remove it (it uses the same key as the POWER switch). This pro-tects the computer—the operator must turn off the high-voltage switchbefore shutting down the machine. Using two keys or bypassing this safe-ty voids all warranties, whether expressed or written.

OUT INARM SWING ARM SWING (two-position selector switch)

This swings the arm to the center of the tire. You must set this switch toIN before you can lower the probe into the tire.

UP DOWNINSIDE INSIDE (two-position selector switch)

Controls the placement of the probe inside the tire.

STEEL FABRIC

STEEL FABRIC

12/7/94 16

CONTROLS

MANUAL MANUAL (black push button)

If a flaw is detected, the tire will stop rotating and the yellow flaw lampwill light. When you depress this button 1⁄2 way, the test arc will be gener-ated. If you depress the button all the way, you will generate the arc androtate the tire. This helps you locate the flaw. When you remove your fin-ger, the test will stop and so will tire rotation.

START START (dark-green push button)

When you press this green button, the test starts, the computer is in thetest mode, and the tire starts rotating. ALSO, press this button again afterany flaw is detected to restart the test.

FOR REVOFF MOTOR DIRECTION (Three-position selector switch)

This switch changes the direction of the tire rotation and turns off themotor. During tire testing, this switch must be in the FOR position so thetire rotates in a clockwise direction. The little yellow and black rotationarrow on the machine shows the correct rotating direction for the rubbercovered roller. You may reverse the direction to find the flaw, but duringthe normal test run, this switch must be in the FOR position.

FLAW

FLAW (yellow 12-volt light)

Warns of a flaw in the tire. When the NDT®-INSP 2 detects a flaw, themachine stops and the FLAW light goes on.

This light also has a press-to-test feature to test the circuit. If the light goeson when pressed:

– The light bulb is okay– The 12-volt power supply is okay

12/7/94 17

CONTROLS

0 100

80

MOTOR ROTATION SPEED

This knob controls the speed of the tire’s rotation. Position “0” is the slow-est speed, and position “100” is the highest speed. Moving this controlknob between these two settings will increase or decrease the speed of thetire rotation.

We recommend that you set the rotation speed at “80” for best results.

FOOT PEDAL SWITCHES (3)

These pedal switches allow you to start tire rotation when you are awayfrom the control panel.

TESTOVER

NORM REVOFF

TEST OVER (green 12-volt light)

Shows when the timer has reached zero and the test is timed out. Thislight only indicates when the electronic test has timed-out. It does notimply that the tire has been completely checked or that the visual test isover. We recommend marking the tire to ensure that it has had a com-plete rotation (see the HELPFUL SUGGESTIONS section).

This light also has a press-to-test feature to test the circuit. If the light goeson when pressed:

– The light bulb is okay– The 12-volt power supply is okay

DIRECTION CHANGE SWITCH (onother side of the NDT®-INSP 2)

This switch allows you to change thedirection of tire rotation from theother side of the NDT®-INSP 2. TheNORM position on this switch per-mits the motor to run in the samedirection as selected by the switchon the control panel.

Direction ChangeSwitch

12/7/94

STEP 1 Air Supply

Make sure machine’s air supply is connected to the filter/ regulatorand air supply is clean and dry. Daily, check and

• Drain filter on machine’s air supply• Make sure machine’s regulator is set to 40 psi (2.7 bar).

☞NOTE: This regulator has nothing to do with the tire liftbecause the tire lift receives its air from the lineair supply hose, not through the regulator.

STEP 2 Power

Make sure the machine is connected to the correct electric powersource.

NOTE: The spread on the tire should be relaxed when rotat-ing the tire.

18

OPERATION

STEEL FABRIC

STEEL FABRIC

TESTOVERFLAW

OUT INARM SWING

UP DOWNINSIDE


OFFONPOWER

OFF ONHIGH VOLTAGE

0 100

50

STEP 5

Turn the FOR/OFF/REV switch to the FOR position.

STEP 4

Remove the key from thePOWER switch and put it into the HIGH VOLTAGE switch.

Turn the HIGH VOLTAGE switch to ON.

STEP 3

Turn the POWER switch to ON with the key.

12/7/94 19

OPERATION

STEEL FABRIC

STEEL FABRIC

TESTOVERFLAW

OUT INARM SWING

UP DOWNINSIDE


OFFONPOWER

OFF ONHIGH VOLTAGE

0 100

50

STEP 11

Press the START button.

STEP 10

Put the INSIDE switch inthe DOWN position. Relaxthe spread on the tire.

STEP 8

Put the ARM SWING switchin the IN position.

STEP 7Select the correct mode forthe tire—either FABRIC orSTEEL.

STEP 9

Lower both sets of beadrollers and spread thetire.

STEP 6 Place a tire up on the spreader using the tire lift.

IMPORTANT: If the lift does not have enough power to lift thetire, the air to the lift valve must be increased. Do not do thisby turning up any valve or regulator shipped with thismachine.

The first four (4) steps are only necessary each time you turn on the machine. It is notnecessary to do the first four steps for every tire.

Testing the Tire

STEP 12 If the tire stops, check the FLAW light.

• If the FLAW light is on, you can press the MANUAL buttonto find the flaw.

• If the green TEST OVER light is on, the automatic test hastimed out.

STEP 13 If the tire test is over you can:

1. Finish the visual inspection.

2. Restart the electronic test.

3. Remove the tire.

– Turn the INSIDE switch to UP.

– Release the spread.

– Remove the bead rollers.

– Turn the ARM SWING switch to OUT.

– Remove the tire.

STEP 14 To check another tire, go back to step 5. It is not necessary to gobackto Step 1.

IMPORTANT: Do not leave the machine or power onovernight, over the weekend, or for any long period of time.

OPERATION

2012/7/94

Shutting Down the Machine

OPERATION

2112/7/94

STEEL FABRIC

STEEL FABRIC

TESTOVERFLAW

OUT INARM SWING

UP DOWNINSIDE


OFFONPOWER

OFF ONHIGH VOLTAGE

0 100

50

STEP 1

Turn the HIGH VOLTAGEswitch to OFF.

STEP 3

Turn the POWER switchto OFF.

STEP 2

Remove the key from theHIGH VOLTAGE switch and put it into the POWERswitch.

IMPORTANT: Do not leave the machine or power on overnight, over the weekend, or for any long period of time.

Step 1. Loosen the clutch screw. (Fig. 14).

This screw secures the probeto the NDT®-INSP 2. Turn theclutch screw counter clock-wise. After you begin loosen-ing it with one hand, holdthe probe with the other sothat it will not fall off and bedamaged.

Step 2. Remove the test probe head(Fig. 15).

The probe head slides out-ward from the housing towhich the clutch screwsecures it.

Step 3. Insert the new test probehead by lining up the twowhite plastic squares on theNDT®-INSP 2 with the probesquare. Place the squaresinto position and hold themthere with one hand whiletightening the clutch screwwith the other hand.

Note: Because of the clutchmechanism in the clutchscrew, you need not worryabout over-tightening it.

OPERATION

2212/7/94

Changing the Tire Test Probe

Figure 14

Figure 15

12/7/94

FOR REVOFFMANUAL

23

OPERATION

Operating Tips

1. The NDT®-INSP 2 mirror will help you find flaws that are out of sight (Fig. 16).

Figure 16

2. Using the MOTOR DIRECTION switch together with the MANUAL but-ton will help you find defects.

Sometimes you will have to rotate thetire back and forth over an area beforeyou can see the flaw. You can use theMOTOR DIRECTION switch to do this.After setting the direction of the motor,you can rotate the tire by pressing theMANUAL button all the way down andholding it. When you want to stop rota-tion, lift up on the MANUAL button.

NDT Mirror®

Spark from arcing

12/7/94

MAINTENANCE

24

The Hawkinson NDT®-INSP 2 is designed to provide years of heavy-duty servicewith minimal maintenance. Most calls for assistance that we receive are becausethe cables from the Control Cabinet have become loose or worn. This is the firstthing you may wish to check if you are experiencing difficulties.

We recommend you replace the high-voltage cable (cable 7 in Figure 10) once ayear.

Periodically check the following items to insure dependable service:

Mechanical

✓ The yellow high-voltage cable connecting running the control cabinet to thehigh-voltage probe of the Inspector should not pull tight, and contact withmetal parts should be minimized.

✓ The black coax cable from the 4” x 4” transformer box on the swing arm to the12” x 10” box on the control cabinet should be unrestricted by other wires orobjects and tightly secured at both ends.

✓ The ground cable connecting the control cabinet to the Inspector should beconnected and secured tightly.

✓ The air pressure at the main regulator should be 40 psi (2.7 bar). The downpressure of the high-voltage probe should be 2 psi (0.33 bar). The up pressureon the high-voltage probe should be just enough to raise it without stressingthe tire sidewall if it makes contact when rising.

✓ The chains and the high-voltage probe must be clean and all chains should bethere.

✓ The probe should track inside the tire properly. To check the probe tracking,use a tire that is not out of round or worn unevenly on the crown radius. Theprobe should always be straight and in the center of the tire.

✓ The metal drive roller and probe should be kept clean.

✓ The plastic sleeves on spreader arms should be free from wear and spin freely.

12/7/94 25

MAINTENANCE

Electrical

✓ Fuses

• Fuse #4 is a 1-amp fuse for the 12-volt DC power supply, which powersthe control box, FLAW and TEST OVER lights, and the relays found inthe control cabinet. The relay under the cabinet lid enables the motor torun when the Branick foot pedal switch is depressed. The lower relayactivates the 50,000-volt DC power supply.

• Fuse #3 is a 2-amp fuse for the 50,000-volt DC power supply, which gen-erates the voltage for tire testing.

✓ High-voltage test

• This test should be performed only after receiving instruction from a quali-fied person, because there are many safety considerations when conductingthis test. NO TIRE SHOULD BE MOUNTED ON THE SPREADER DURINGTHIS TEST!

• Turn the POWER switch ON, the HIGH-VOLTAGE switch ON, the ARMSWING selector to IN, and the MOTOR selector to OFF.

• Spread the spreader arms enough to allow the probe to lower.

• With your right hand, hold the upper bar above the high-voltage probe.Turn the INSIDE switch to DOWN, and exert enough force on the upper barto keep it from lowering.

• Push the START button with your left hand. (Be careful not to touch thehigh-voltage elements on the high-voltage probe.) The high-voltage ele-ments on the probe include the chains, the chain holder, the wheels, thesidewall wires and all metallic parts conntected to them.

• The voltages inside the cabinet are lethal!

• Never operate the machine with the control cabinet door open!

• Be sure the electrical connections are properly grounded. Note thatin North America the 120-volt plug is polarized.

DANGER!

• Allow the high-voltage probe to slidedown slowly until an arc occurs betweenthe probe and the roller. The high-voltageturns off automatically when the arcoccurs.

• Look at the NDT TEST GAUGE on theslide track and the pointer on the clevis ofthe UP/DOWN cylinder.

• When testing in the FABRIC mode, thepointer should point to the blue dot.When testing in the STEEL mode, thepointer should point to the green dot.

Note: You cannot generate a high voltagewhen the INSIDE or HIGH VOLTAGEswitches are in the UP or OFF mode,respectively.

MAINTENANCE

2612/7/94

STEEL

FABRIC

0

1

2

3

NDTTEST

GAUGE

BlueDot

GreenDot

Before Calling for Assistance....

If your machine develops a problem, before you call, please do the following:

❏ Check the fuses. A list of the NDT INSP 2 fuses is included on page 26.

❏ Check the condition of the cables connecting the Control Cabinet to

the Inspector to make sure all are tightly secured.

❏ Check the tire construction—Is the tire bias or radial? Is the tire tube

or tubeless?

❏ Check the tire size—is the problem occurring for just one size, or sev-

eral different sizes?

❏ Especially, find out if the trouble is occurring in BOTH FABRIC and

STEEL modes, or is the trouble limited to just one of the modes?

❏ If the NDT®-INSP 2 is missing penetrations, please note:

1. Is the high-voltage arcing to the penetration?2. Is the penetration all the way through the tire?

❏ Have the NDT®-INSP 2 serial numbers and computer numbers athand

This will help us diagnose the problem more quickly and accurately.

HAWKINSON TREADING, INC.1325 Winter Street N.E.

Minneapolis, MN 55413 USA

Phone (612) 331-1397 • FAX (612) 331-6569

MAINTENANCE

2712/7/94

12/7/94 28

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Quantity and Part Number Description

Electrical

1 of ZB2–BG2 2-position key lock with release from left2 of ZB2–BZ1026 NC low-voltage base and block5 of ZB2–BE101 NO high-voltage block only1 of ZB2–BE102 NC high-voltage block only1 of ZB2–BG4 2-position key switch release from either position1 of ZB2–BZ102 NC high-voltage base and block1 of ZB2–BE102 NC high-voltage block only (For 220V model only)2 of ZB2–BV6–120 120-volt pilot light and base2 of ZB2–BW061–12 12-volt press-to-test pilot light and base1 of ZB2–BV04 Red pilot light cover1 of ZB2–BV05 Yellow pilot light cover1 of ZB2–BV051 Yellow press-to-test pilot light cover1 of ZB2–BV031 Green press-to-test pilot light cover1 of ZB2–BA3 Green flush-head switch1 of ZB2–BZ1016 NO low-voltage base and block1 of ZB2–BA2 Black flush-head switch2 of ZB2–BE1016 NO low-voltage block only3 of ZB2–BD2 2-position selector switch2 of ZB2–BE1026 NC low-voltage block only1 of ZB2–BZ105 NO and NC high-voltage base and blocks1 of ZB2–BZ101 NO high-voltage block and base

Mechanical

1 of F724-30-B7-J1 Boston gear reducer1 of 56591 Base for Boston gear reducer1 of PM9100TF-B 1-hp variable speed DC motor 1 of 40BS14-1-1-1/8 40–B–14 Chain sprocket, 1-1/8” bore1 of 40BS23-1 40–B–23 Chain sprocket, 1-inch bore2 of 40B515-1 40-B-15 Chain sprocket, 1-inch bore1 of BNDT II–chain # 40 roller chain3 of 98–W–2 Dual V wheel2 of 98–B–2 Fixed bushing for dual V wheel

PART NUMBERS

3312/7/94

1 of 98–BX–2 Adjustable bushing for dual V wheel2 of 5L1 1-inch pillow block bearing2 of 98–T–2–24 24-inch length of #2 dual V rail1 of TEI TEI Motor controller, North American: 115V, 60 hz.

Foreign: 220-volt, 50 hz. or 200 volts, 60 hz.Air2 of 11SAD400C 120-volt, 60/50 cycle, 4-way solenoid valve2 of 229–310 Speed control assembly2 of 103–165B 1/8-inch, 5-ported base2 of 230–213A 4-foot yellow electrical cord1 of 229–468A Double regulator on valve package1 of PCG-02-H00 Wilkerson 1/4-inch filter regulator on all machines1 of GRP–95–228 0 to 60 psi gauge, 1/8” back fitting1 of GRP–95–229 0 to 160 psi gauge, 1/4” back fitting on all machines1 of GPA–95–012 Mounting bracket for Wilkerson regulator1 of BIM-D-39320-A 1-1/4” bore, 12” stroke BIMBA cylinder1 of BIM-D-39319-A 2” bore, 6” stroke BIMBA cylinder1 of BIM-231-1 Clevis—rod end for 1-1/4” by 12” cylinder1 of BIM-231-3 Clevis—rod end for 2” by 6” cylinder4 of 127–248 Stud bolt for Numatics4 of 128–153 Nut for above stud #127-2484 of 128–144 Lock washers for above two items2 of 113–175A Gasket for valve to base on Numatics5 of 50–57944 90-degree 1/4” tubing to 1/4” pipe Polymatic fitting1 of 50–56844 Straight 1/4” tubing to 1/4” pipe Polymatic fitting2 of 50–57942 90-degree 1/4” tubing to 1/8” pipe Polymatic fitting2 of 50–57842 Straight 1/4” tubing to 1/8” pipe PoAlymatic fitting1 of 112-C-50 Safety valve set at 50 psiK71DA00-KCO-KLI Lift Valve—NorgrenK81DA00-KCO-KL2 Spread Valve—Norgren

Decals Available at no charge

DANGER-1 Figure 2 on page 5WARNING-1 Figure 1 on page 4NDT PROBE Figure 3 on page 5

PART NUMBERS

3412/7/94

12/7/94 35

INSTALLATION

The Branick Tire Inspector is shipped completely assembled.All that is necessary to prepare it for service Is to connect anair line to the fitting at the lower left end of the machine and towire the electrical box. It is important that the electrician wirethe electrical box correctly. There is .an arrow on the motorindicating the correct direction of rotation. The motor Is 2 H.P.,230 volts, 3 phase, unless ordered special. The light cordshould be connected to a 115 volt single phase power source.

OPERATING INSTRUCTIONS

The normal operators position is facing the machine with thetire lift on the right hand side and the air control valves just tohis right.

Push the “Start” button at the “Start-Stop” switch when readyto inspect tires. The rollers .will not revolve until a foot pedal isdepressed. Stepping on any of the three pedals, front, rear orlift end will activate the rollers.

Pull the bead hooks up and away from the center of themachine. With the tire lift on the floor, roll the tire onto the liftcradle. Actuate the tire lift air valve (LOWER VALVE OFCLUSTER) and raise the tire onto the machine between thetraction rollers.

Place the bead hooks between the tire beads using the han-dles provided. If the beads are very close together, drop in onebead hook and carefully tip the tire, to open the beads. Thiswill allow room for the other bead hook.

Place the light inside of the tire. The light is fully adjustableand can rotate to view any portion of the tire.

With the bead hooks engaged and the light inside of the tire.press on a foot pedal to rotate the tire. Spread the tire todesired width by operating the spread air valve (TOP VALVEOF CLUSTER). The tire can be stopped in any position byreleasing the foot pedal.

CAUTION—After the tire has been inspected:1. Stop tire rotation by releasing foot pedal2. Release spread cylinder completely 3. Remove bead. hooks from tire4. Roll tire onto lift cradle and lower to floor.

ADJUSTING SPREAD HOOKS

There are three spread arm height positions. Most tires can beInspected with spread arms in one position on the powerarms. The spread arms are held in position with spring loadedlock pins. To release the pins, place hands under horizontalbar and with the thumb release the lock and slide the spread

arm assembly up or down. The locks will pop into the newposition when centered on the hole.

If the tire is lifted off of the traction rollers when the tire isspread, the arms should be lowered to the next position.

NOTE—RADIAL TIRES

When inspecting some radial tires, the tire may shift to theright and collapse. To prevent this the tire lift can be lockedinto position to hold the tire centered on the traction rollers.There are two methods Of locking the tire lift into position.

1. At the time the tire is lifted onto the machine, the opera-tor can push the tire forward enough to latch the twolocks which are on each side of the lift cradle. Once thelocks are secured, the tire can be inspected in the normalmanner.

2. If the tire is already on the machine with the bead hooksin position. the operator can lower the lift slightly, raisethe lift cradle by hand and secure the locks. When thelocks are secure, the lift can be brought up against thetire to hold it centered on traction rollers.

CAUTION—THE LOCKS MUST BE RELEASED BEFORE USING THE LIFT TO LOWER THE TIRE TOTHE FLOOR.

MAINTENANCE

CAUTION—DISCONNECT POWER SOURCE (AIR ANDELECTRIC) BEFORE SERVICING MACHINE.

The chain idlers are equipped with zerk fittings and should begreased every six months.

The vertical posts should be cleaned and waxed periodically toallow hook assemblies to slide easily.

Once a month pour about 1/4 cup of 10 or 20 SAE motor oilinto each air cylinder. Each six months remove air cylindercover plates and remove piston and rod. Clean cylinder thor-oughly. After reassembling cylinders, add 1/4 cup of Oil tospread cylinder through plug in pipe tee and to lift cylinderthrough plug in cover plate.

Operating InstructionsRevolving Type

Truck Tire SpreaderMODEL S-FLL/ ER/EFRetread Equipment Automotive Division

®

®®

12/7/94 36

ITEMNO.

PARTNO.

NO.REQ’D DESCRIPTION

ITEMNO.

PARTNO.


2 1 Right Spread Arm 43 116.098 1 Front Panel3 1 Front Spread Arm 44 81.098 1 Lower R.H. Panel4 187.900 1 Spread Cylinder 45 84.098 1 L.H. Panel (not shown)5 12.928 1 Lift Cylinder 46 82.098 1 Rear Panel (not shown)7 1 Drive assembly 47 28.003 4 Rivet8 553.950 1 Short Link 48 4.003 2 Rivet9 552.950 1 Long Link 50 49.039 2 Lift Lock Bushing

10 1 Link Pivot—Hawkinson 52 329.028 2 3/8 NC HHCS x 211 11.110 1 Spread Cylinder Spring 53 21.028 10 3/8 NC HHCS x 124 5.846 1 Lift Cyl. Link 54 14.028 4 5/16 NC HHCS x 125 14.878 1 Spring Bracket 56 23.055 4 5/16 NC Hex Lock Nut29 28.834 1 Basic Frame 57 210.055 17 3/8 NC Flat Washer30 4.874 1 Lift Yoke 58 15.108 4 3/8 Flat Washer31 27.834 1 Lift Frame 59 6.061 4 1/8 x 1-1/4 Drive Pin32 1.834 1 Front Cradle Catch 60 9.061 4 5/32 x 1 Drive Pin33 2.843 1 Rear Cradle Latch 61 5.061 4 1/8 x 1 Drive Pin34 4.846 2 Lift Cradle Link 62 148.028 38 1/4 Self-Tapping Screw35 81.104 1 Cradle Roller Shaft 63 157.108 2 Spring Washer36 16.107 2 Cradle Roller Brg. 64 46.298 1 Foot Switch Shield Front37 292.268 1 Cradle Roller Tube 65 47.298 1 Foot Switch Shield Rear38 3.826 1 Lift Cradle 66 45.298 1 Food Switch Shield R.H.39 79.098 1 Top Cover, L.H. 68 62.039 10 Bushing40 86.098 1 Top Cover Tray 69 65.039 2 Bushing41 8.825 1 Top Cover RH 70 182.028 9 Self-Tapping Screw42 115.098 1 Upper RH Panel



®®

12/7/94 37

ITEMNO.

PARTNO.


ITEMNO.

PARTNO.


1 3.828 1 Lift Cylinder Weldment 10 4.006 1 1/8 Tapered Caplug2 2.028 3 5/16 NC x 5/8 H.H.C.S. 11 157.096 1 Lift Cylinder Fitting3 239.028 1 9/16 NC x 1-1/4 H.H.C.S. 12 43.039 1 Bushing4 240.167 1 14 Mil Gasket5 32.108 1 Cup Washer6 15.041 1 Piston Cup7 23.051 1 3-1/2 inch Diameter Piston 13 154.061 1 Lift Cylinder Pin8 198.149 1 Piston Rod 14 15.061 1 5/32 x 2 Cotter Pin9 114.098 1 Cover Plate 15 5.061 2 1/8 Diameter x 1 Drive Pin

ITEMNO.

PARTNO.


ITEMNO.

PARTNO.


1 194.950 1 Cylinder2 5.028 4 7/16 NC x 5/8 H.H.C.S. x 3/4 8 1.006 1 1/4 Oil Plug3 204.041 1 Block Vee-Seal 4-1/2 Diameter 9 249.096 1 1/4 Pipe Tee4 195.950 1 Piston Rod Assembly 10 221.096 1 1/4 Close Nipple5 326.041 1 Rod Seal 11 58.055 1 1/2 NC Hex Lock Nut6 327.098 1 Cover Plate 12 25.028 1 1/2 NC HHCS x 1-1/27 4.006 1 1/4 Caplug 13 34.096 1 1/4–1/4 Male Elbow



®®

ASSOCIATED ITEMS NOT INCLUDED IN ASS'Y 187.900

ASSOCIATED ITEMS NOT INCLUDED IN ASS'Y 12.928

Lift Cylinder

Spread Cylinder

12/7/94 38

ITEMNO.

PARTNO.


ITEMNO.

PARTNO.


1 16.804 1 Rear Spread Arm 8 82.104 2 Spring Holder Shaft15.804 1 Front Spread Arm 9 71.055 4 1/2 Hex Cap Nut

2 18.107 4 Bead Roller Bearing 10 79.104 4 Spread Roller Shaft3 83.268 2 Bead Roller 11 13.963 4 Spread Roller 4 4.863 2 Roller Weldment 12 72.055 4 5/8 Hex Cap Nut5 25.110 1 Bead Roller Spring 13 156.028 4 10-24 Pan HD. Screw x 5/86 71.446 4 Sleeve 14 153.061 4 Latch Pin7 82.104 4 1/8 x 3/4 Drive Pin 15 18.110 4 Latch Spring

ITEMNO.

PARTNO.


ITEMNO.

PARTNO.


12 84.980 1 3/8 x 45° Connector 21 1.851 1 Foot Switch—Single13 118.980 1 3/8 Conduit x 36” 22 289.028 1 3/8 NC HHCS x 1-1/214 62.980 1 Micro Switch 23 39.028 1 3/8 NC HHCS x 1-3/415 26.980 1 3/8 x 90° Connector 24 73.110 2 Spring16 210.055 2 3/8 NC Hex Lock Nut 25 2.039 2 Washer17 178.028 1 Fixed Lever 26 51.039 1 Bushing18 31.157 1 3/16 NC Hex Nut 27 24.108 1 3/16 Plain Washer19 75.055 2 3/16 NC HHCS x 1-1/2 28 25.108 2 3/16 Plain Washer20 2.851 1 Foot Switch—Double



®®

12/7/94 39

ITEMNO.

PARTNO.


ITEMNO.

PARTNO.


1 3.863 2 1 Knurled & 1 Rubber coveredTraction Roller

9 PM9100TF 1 Electric Motor 1 hp DC NDT

2 20.107 4 Pillow Block 10 40BS14-1-1/8 1 14-Tooth Sprocket3 21.028 8 3/8 NC HHCS x 1 11 20.251 1 3/16 x 3/16 x 1 Key5 210.055 8 3/8 NC Hex Lock Nut 14 F724-30-B7 1 Gear Box Boston F7246 40BS23-1 1 23- Tooth Sprocket 20 BNDT-Chain 1 Drive Chain7 26.251 4 1/4 x 1/4 x 1-1/4 Key 21 BNDT-Chain 1 Idler Chain8 40BS15-1 2 15-Tooth Sprocket



®®

12/7/94

BOSTON 700 Series Worm Gear Speed Reducers

INSTALLATION, LUBRICATION, and OPERATION INSTRUCTIONS

WARNINGBoston Gear speed reducers are normally shipped without lubricant. They must be filled to the properlevel with the recommended lubricant for your application before operation.

40

Instructions for Flanged Models (NEMA C-Face Mounting)

1. Leave protective sleeves on shafts for safer handlingof speed reducers during installation. The sleeves areprovided to protect your hands from potential sharpedges on keyways.

2. Align all shafts accurately. Improper alignment canresult in failure. Use of flexible couplings is recom-mended to compensate for slight misalignment.

3. When mounting, use maximum possible bolt size andsecure reducer to a rigid foundation. Periodic inspec-tion of all bolts is recommended.

4. Auxiliary drive components (such as sprockets, gears,and pulleys) should be mounted on the shafts as closeas possible to the housing to minimize effects of over-hung loads. Avoid force fits that might damage bear-ings or gears. Projecting input shafts are furnishedwith a keyway and, except for Models 710, 715, and724, with an axially tapped hole. Models 732 through760 are supplied with axially tapped holes on bothends.

5. For hollow-shaft speed reducers, place speed reducer asclose as possible to supporting bearing on driven shaft.

Spot-drill driven shaft for set screws in severe applica-tions. See kit instructions for reaction rod assembly.

6. Check and record gear backlash at installation andagain at regular intervals. This should be done by mea-suring the rotary movement of the output shaft (rotatingalternately clockwise and counterclockwise at a suitableradius while holding the input shaft stationary. Gearsshould be replaced when the backlash exceeds fourtimes the measurement taken at installation.

7. Gear drives are rated for 1750 input RPM and Class IService (Service Factor 1.0), using Mobil SHC B34synthetic lubricant. For lower input speeds or for dif-ferent service classes or lubricants, see catalog for rat-ing information.

8. Initial operating temperatures may be higher than nor-mal during the break-in period of the gear set. FORMAXIMUM LIFE, DO NOT ALLOW THE SPEEDREDUCER TO OPERATE CONTINUOUSLY ABOVE225°F. AT THE GEAR CASE. In event of overhearing,check for overloads or high ambient temperatures.Keep shafts and vent plugs clean to prevent foreignparticles from entering seals or gear housing.

General Instructions

RF700 (Coupling Input -- One-Piece Sleeve Type) 1. Remove protective sleeve from input shaft.2. Assemble the key provided and coat the reducer input

shaft with anti-seize compound, also provided. (Anycommercial anti-seize compound may be substituted.)

3. Slide the coupling half on the reducer input shaft untilthe coupling bottoms.

4. Assemble the key to the motor shaft and coat the shaftwith anti-seize compound. Insert the motor shaft intothe coupling bore.

5. Rotate the motor to proper position and firmly secureto flange with four hex-head cap screws.

F700 (Quill-Type Input)1. Assemble the key to the motor shaft and coat the shaft

with anti-seize compound. Insert the motor shaft intothe reducer input shaft.

2. Rotate the motor to proper position and firmly secureto flange with four hex-head cap screws.

RF700 (Coupling Input—Flexible-Jaw Type FC)—Optional1. Coat reducer input and motor shaft with anti-seize

compound.2. Position coupling half on input shaft with shaft flush to

end of coupling bore.3. Locate remaining half on motor shaft, with 1/32" clear-

ance between jaw surfaces.4. Tighten set-screws securely. For reversing applications,

a thread-locking compound is recommended.5. Install coupling insert and position motor. Rotate motor

to proper position and firmly secure to flange.CAUTION—If the motor does not readily seat itself, checkto determine if key has moved axially along motor shaft,causing interference.

12/7/94

BOSTON GEAR 700 Series Worm Gear Speed Reducers

SINGLE-REDUCTION MODELS PARTS LIST

41

PART ORDERING INFORMATION

1. Be sure to provide complete the Boston Gear catalog number from the speed reducer nameplate, along withpart description and number. For example: “One output oil seal, part no. 11, for RF718-30-B5-G.”

2. Ouput shaft components for Boston Gear Models 710 through 726 are available only as complete assembliesthat include parts 2, 3, 5, and 6 for single projecting shafts; and parts 2, 4, 5 and 6 for double projectingshafts. When ordering, specify “output shaft assembly” and the full Boston Gear catalog number from thenameplate.

MODELS 710–760

12/7/94

OPTIONS AND ACCESSORIES

42

PARTNO. DESCRIPTION

1 HOUSING 2 WORM GEAR3 SINGLE PROJECTING OUTPUT SHAFT 4 DOUBLE PROJECTING OUTPUT SHAFT 5 GEAR SPACER 6 OUTPUT BEARING (CONE)- MODELS 713 760 7 OUTPUT BEARING (CUP) MODELS 713 760 8 OUTPUT BEARING MODEL 710 ONLY 9 BEARING CARRIER (OPEN)

10 BEARING CARRIER (CLOSED) 11 OUTPUT OIL SEAL 12 ADJUSTMENT SHIMS 13 INPUT WORM SHAFT 14 INPUT BEARING MODELS 710-726 15 INPUT BEARING RETAINER 16 INPUT OIL SEAL MODELS 710-760 17 RETAINING RING 18 ADJUSTMENT SHIMS 19 BORE PLUG- MODELS 710 726 20 INTERNAL Baffle MODELS 713 732 22 INPUT 0 RING 23 OUTPUT 0'* RING 24 H[X HEAD CAP SCREW 25 HEX HEAD CAP SCREW

PARTNO. DESCRIPTION26 VENT PLUG 27 PIPE PLUG28 PROTECTIVE CAP PLUG 29 INPUT KEY 30 OUTPUT KEY 31 NAMEPLATE 32 INPUT BEARING (CUP)-MODELS 732 760 33 INPUT BEARING (CONE) MODELS 732-760 34 GREASE CUPS MODELS 732 760 35 HEX HEAD CAP SCREW 37 OUTPUT SHAFT KEY-MODELS 732 760 38 RETAINING RING- MODELS 710 738 39 MOTOR SHAFT- MODELS 710 738 40 MOTOR FLANGE MODELS 710-738 41 OIL SEAL-MODELS 710 738 42 HEX HEAD CAP SCREW 43 HORIZONTAL BASE 44 HEX HEAD CAP SCREW 45 LOCKWASHER 46 SLEEVE COUPLING 47 RETAINING MOTOR FLANGE 48 RISER BLOCK 49 HEX HEAD CAP SCREW 50 VERTICAL BASE (HIGH OR LOW)

PARTNO. DESCRIPTION51 HEX HEAD CAP SCREW 60 VERTICAL BASE (X & Y ASSEMBLY)

101 FAN 102 LOCKWASHER 103 HEX HEAD CAP SCREW 104 FAN GUARD 105 HEX HEAD CAP SCREW 106 WASHER 111 HOLLOW OUTPUT SHAFT 112 WORM GEAR 113 GEAR SPACER 114 OUTPUT BEARING (CONE) 115 OUTPUT BEARING (CUP) 117 OIL SEAL 119 BEARING CARRIER (OPEN) 120 KEY (EXTERNAL) 121 KEY (Internal 122 "V TYPE BASE 123 SOCKET SETSCREW

HOLLOW OUTPUTSHAFT MODELSS, SF, and SRF718-732

MODELS F710–F738 MODELS RF710-RF760PARTS ADDED TO 710-726 OR 732-760THESE PARTS AVAILABLE IN KIT FORM.

FAN KIT FOR MODELS 732–760

MODELS 732–760

HEADER

4312/7/94

HEADER

4412/7/94

HAWKINSON NDT -INSP 2, REBUILD & UPGRADE NDT®-INSP 2, REBUILD & UPGRADE OPERATOR’S MANUAL ® The...

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